Cover Article: A day in... The Production Department.

A day in… The Production Department.

The strength of the harmony of the group.

The harmony of the group is the trump card for a constant, continuous production of quantity but above all quality; an artifact is affected by the processing of multiple departments within the production cycle, so many different people work on the same level; it is absolutely necessary for each department to manage the product with a certain care and precision, for an excellent final result.

1st Stage: Technical Office

The production cycle does not start in the production sector, but from our technical office, headed by Francesco, who transforms an order into a technical drawing of production. He also verifies the stock of raw materials in the storage and / or deciding whether a whole slab or the so-called “Filagne” will be used for the execution of the product, i.e. pieces of slabs used previously for the execution of a product, but from which there is the possibility of obtaining a second one.

2nd Stage: Milling

Once this phase has been completed, the technical drawing is delivered to the milling worker, the one responsible for the cutting process of the product. In this sector Renato and Mauro work for us, who, once they have studied the drawing and identified the material in the warehouse, before picking up a slab check (and this is the first quality control) that it has no imperfections both chromatic and structural.

3rd Stage: The Production department

Once we’re sure, and this happens outside the production shed, that the material is suitable for the realization of the Top, through an appropriate crane and the following slabs-holder carriage, the slab is inserted inside the production.  

The first phase consists in positioning the slab over the cutter bench; at this point the second quality control takes place, through a special photography system (a system that photographs the slab and highlights any imperfections), it is definitively ascertained that the material is suitable. The cutting or milling phase of the product has different execution times, depending on the type of material that has to be cut: much faster for quartz and natural stones, very slow for ceramics and Dekton. It must be considered that the time range can go from 30 minutes to 3 hours; of course, another variant is the size of the product to be made.

After this first activity, the still unfinished Top is moved to another department, giving way to the second phase, exactly in the workstations of Luciano, who – with the use of machines called “lucida coste” – carries out the finishes of the perimetral edges of the product.

The third phase consists in a further quality control: the artifact arrives at the Flow station, guided and programmed by our operator Deives, who works with advanced autocad programs and has the task of executing the holes of the sink, of the hob and / or other holes provided for the Top (tap hole, kitchen utensil holder hole, hole for separate collection / wet waste collection, etc.). In this workstation, if there are dimensional errors, they are immediately detected, since the autocad program (which then manages the Flow) immediately signals the error, if the measurements are wrong.

The fourth phase is random. There is another production station, which is not mandatory, however, we refer to the possible use of the shape-milling machine, managed by our Guglielmo. In this workstation, the artifact stops and undergoes processing if the artifact consists of filo-top sinks or under-top integrated. This machine, again numerically controlled, is used to make grooves and / or partially remove the raw material, so as to guarantee the coplanarity of the surface after laying the sink made of other material, or the hob.

The top goes towards the finishing benches station in the fifth phase, third quality control, where Michele, Moreno and Pietro, before getting ready to check the juxtaposition of the pieces, the shade and subsequently the finishes that can be glued or small final adjustments made by hand, check the top’s correspondence to the detailed executive drawing, previously prepared by our technical office. In this finishing workstation, a top can stop for a few minutes only for checks or even days in the case of sinks under-top or integrated reconstructed sinks. There are technical maturation times of the adhesives used, which subsequently must also be finished by shaving with a grinding wheel or, many times, to reach perfection, with manual elbow grease, with abrasives of various size.

We are at the last stage – the sixth phase – and the last quality control, that of the packaging and cleaning of the product. Marcello has been working here for over 25 years, he first makes a further general dimensional check (the dimensional checks are multiple, but the error cannot exist: the millimetre often makes the difference between a good job and an excellent job), then he cleans up the top completely to check if there are imperfections. Once the quality of the work is certain, it is packaged, which in Masutti is considered to be a very important thing: clumsy handling of top items that are delivered all over the world, if not well packaged, increase the risk of breakage. At this point, the top is ready for our customer’s collection (20% of the cases), or to be delivered by us (80% of the material produced); Gianni, our employee carrier, with his own vehicle, traveling throughout the length and breadth of Triveneto, punctually delivers within the timeframe.

We have tried in a few lines to explain how a kitchen top is produced; we hope to have been helpful to those interested in this type of information. We always try to do things well!

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